Hygro Flat Woven Fabrics, Articles, And Related Processes

ABSTRACT

A woven fabric and related process that includes hygro yarn structures with hollow cores that formed into flat woven fabrics suitable for bedding applications.

TECHNICAL FIELD

The present application claims priority to and the benefit of IndianApplication No. 201721019852, filed Jun. 6, 2017, the entire disclosureof which is incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to hygro flat woven fabrics, articles,related processes for making same, and in particular to hygro flat wovenfabrics and articles adapted for home textile uses, such as bedding.

BACKGROUND

Hygro materials can be used to describe materials, such as yarns andfabrics, which absorb water or moisture. Textile materials can absorbwater through the fiber structure itself. For instance, cotton fibersare highly absorbent and textile materials that use cotton fibers can beabsorbent materials. Textile materials can also be designed to absorbmoisture through the specific yarn and woven fabric constructions. Forexample, lightly twisted yarn structure may absorb more moisture thanhighly twisted yarn structures. In another example, terry fabrics cantypically absorb more moisture than flat fabrics due to the presence ofpiles and increased surface area available to absorb and transportmoisture. It is challenging to balance the ability of a fabric structureto absorb moisture while also maintaining fabric durability andsoftness. This effort is further challenged by developing yarnstructures that can readily withstand the rigors of weaving or othertextile processes.

SUMMARY

A first embodiment of the disclosure is a woven fabric that includesplied staple yarns that include hollow cores. The woven fabric includesa warp component including warp yarns and a weft component includingweft yarns interwoven with the warp yarns to define the woven fabric. Atleast one of a) the warp component, and b) the weft component include aplurality of the plied staple yarns. Each plied staple yarn has a lengthand a plurality of separate package dyed staple yarns twisted together.Each package dyed staple yarn includes an outer sheath of staple fiberstwisted together, and a hollow core within the outer sheath of staplefibers. The hollow core extends along the length of the plied stapleyarn. One example of the first embodiment of the present disclosure is abedding article that includes the woven fabric described above. Thebedding articles formed from the first embodiment of the woven fabricincludes one or more of a flat sheet, a fitted sheet, a pillow case, acomforter, and a pillow sham.

A second embodiment of the present disclosure is a process formanufacturing a flat woven fabric that includes the plied staple yarnsthat include separate package dyed yarns each having a hollow core. Theprocess includes spinning a first staple yarn to include a first outersheath of staple fibers twisted around a first inner core of watersoluble fibers, and spinning a second staple yarn to include a secondouter sheath of staple fibers twisted around a second inner core ofwater soluble fibers. The process includes plying the first staple yarnand the second staple into a plied staple yarn. The plied staple yarn iswound into a yarn package. With the plied staple yarn on the yarnpackage, the first and second inner core of the water soluble fibers areremoved from each one of the first and second staple yarns in the pliedstaple yarn to form first and second hollow cores in the first andsecond staple yarns, respectively. After the removing step, the processincludes weaving a plurality of the plied staple yarns into a flat wovenfabric. In one example of the second embodiment, the weaving stepincludes weaving a flat woven fabric having warp yarns and weft yarnssuch that at least one of the warp yarns and the weft yarns include theplied staple yarns. In another example of the second embodiment, theremoving step can also include dyeing the outer sheath of staple fibers.

A third embodiment of the present disclosure is a flat woven fabric thatinclude multi-core staple yarns. The flat woven fabric includes a warpcomponent including warp yarns, and a weft component including weftyarns interwoven with the warp yarns to define the woven fabric. Atleast one of a) the warp component and b) the weft component include aplurality of multi-core staple yarns. Each multi-core staple yarnincludes a length, an outer sheath of twisted staple fibers that extendsalong the length, a first hollow core that extends through the outersheath of staple fibers along the length, and a second hollow core thatextends through the outer sheath of staple fibers along the length. Inone example of the third embodiment, the first hollow core and thesecond hollow core are twisted around and with respect to each other aseach extends along the length. Another example of the third embodimentof the present disclosure is a bedding article that includes the wovenfabric with multi-core staple yarns. The bedding article includes one ormore of a flat sheet, a fitted sheet, a pillow case, a comforter, and apillow sham.

A fourth embodiment of the present disclosure is process formanufacturing a woven fabric that includes multi-core staple yarns. Theprocess includes spinning staple yarns to include an outer sheath ofstaple fibers twisted around a first core of water soluble fibers and asecond core of water soluble fibers. The process further includesremoving the first and second cores of water soluble fibers from eachone of the staple yarns to from a multi-core staple yarn having thefirst and second hollow cores. The process includes weaving themulti-core staple yarns into a flat woven fabric. In one example of thefourth embodiment, the weaving step includes weaving warp yarns and weftyarns with each other to define the flat woven fabric such that at leastone of a) the warp yarns, and b) the weft yarns include the multi-corestaple yarns. In one example of the fourth embodiment, the weaving stepoccurs after the removing step. In another example, however, the weavingstep occurs before the removing step. In yet another example of thefourth embodiment, the removing step includes dyeing the multi-corestaple yarns.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofillustrative embodiments of the present application, will be betterunderstood when read in conjunction with the appended drawings, whichare described below. For the purposes of illustrating the presentapplication, there is shown in the drawings illustrative embodiments ofthe disclosure. It should be understood, however, that the applicationis not limited to the precise arrangements and instrumentalities shown.

FIG. 1A is a schematic view of a woven fabric formed with hygro yarnsaccording to an embodiment of the present disclosure.

FIG. 1B is a cross-sectional view of the woven fabric taken along line1B-1B in FIG. 1A.

FIG. 2 is a sectional side view of a terry fabric woven including hygroyarns according to another embodiment of the present disclosure.

FIG. 3A is a schematic side view of a hygro yarn used in to form thefabrics illustrated in FIGS. 1A-2B;

FIG. 3B is cross-sectional view of the hygro yarn taken along line 3B-3Bin FIG. 3A, and illustrating the water soluble fiber core.

FIG. 4A is a schematic side view of the plied hygro yarn illustrated inFIG. 3A, after the water soluble fiber core has been removed.

FIG. 4B is cross-sectional view of the plied hygro yarn, taken alongline 4B-4B in FIG. 4A, and illustrating the hollow core after the watersoluble fiber core has been removed.

FIG. 5 a process flow diagram for manufacturing the plied hygro yarn,according to an embodiment of the present disclosure.

FIG. 6 a process flow diagram for manufacturing textile articles withthe plied hygro yarns, according to an embodiment of the presentdisclosure.

FIG. 7A, is a schematic side view of the multi-core hygro yarn used infabrics illustrated in FIGS. 1A-2B;

FIG. 7B is cross-sectional view of the multi-core yarn, taken along line7B-7B in FIG. 7A, and illustrating the first and second water solublefiber core.

FIG. 8A is a schematic side view of the multi-core hygro yarnillustrated in FIG. 7A, after the first and water soluble fiber coreshave been removed.

FIG. 8B is cross-sectional view of the multi-core yarn, taken along line8B-8B in FIG. 8A, and illustrating the first and second water solublefiber core.

FIG. 9 a process flow diagram for manufacturing the multi-core hygroyarn and related fabrics, according to an embodiment of the presentdisclosure.

FIG. 10 a process flow diagram for manufacturing textile articles withthe multi-core hygro yarns, according to an embodiment of the presentdisclosure.

FIG. 11 is schematic of an apparatus using in yarn spinning according toan embodiment of the present disclosure.

FIGS. 12A and 12B illustrate data related heat loss for certain flatwoven fabrics.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Embodiments of the present disclosure include unique “hygro” textilestructures, such as yarns, fabrics, and related articles that are highlyabsorbent, hydrophilic, soft, and adapted for home textile applications.The hygro textile structures may be suitable for bedding articles, suchas sheeting products. Also described herein are processes and devicesused to manufacture hygro textile structures. The hygro textilestructures as described herein are formed with yarn configurations thatinclude an outer sheath of fibers that surround inner, multiple, hollowcore(s). The multiple hollow cores are formed by the removal of solublefibers, e.g. water soluble fibers, during the manufacturing process, aswill be further explained below.

The yarn configurations described in the present disclosure can have oneof several different structures. In one embodiment, the yarnconfiguration is a plied yarn formed from single end yarns that includea core of soluble fibers, as shown FIGS. 3A and 3B. After the solublefibers are removed, the resulting structure is a plied hygro yarn 80 ofmultiple single end yarns, each of which have a hollow core, as shownFIGS. 4A and 4B. The process used to form the yarn structuresillustrated in FIGS. 3A to 4B will be described in detail below. Inanother embodiment, the yarn configuration is a single end yarn formedto include multiple cores of soluble fibers, as shown FIGS. 7A and 7B.After the soluble fibers are removed, the resulting structure is asingle end, multi-core yarn 180 that includes multiple hollow cores, asshown FIGS. 8A and 8B. The process used to form the yarn multi-core yarn180 illustrated in FIGS. 7A-8B will also be described in further below.The yarn structures that include soluble fibers as illustrated in theFIGS. 3A and 3B and in FIGS. 7A and 7B are referred to in the presentdisclosure as “intermediate yarns.” The yarn structures where thesoluble fibers have been removed as illustrated in the FIGS. 4A and 4Band in FIGS. 8A and 8B are referred to in the present disclosure as“hygro yarns.”

The resulting hygro yarn configurations as described herein in manycircumstances boost manufacturing efficiency and improve end-productquality. For instance, the plied yarn yarns 80 as shown FIGS. 4A and 4Bmay result in fewer end breaks during weaving, increasing weavingefficiency. The plied yarns 80 shown in FIGS. 4A and 4B are alsopackaged dyed yarns, which can result in better color fastness in thefinished product, among other benefits discussed below. For multi-coreyarns 180 shown in FIGS. 8A and 8B, the process used to form the yarns180 results in increased productivity, which in turn, increases overallefficiency along the yarn-to-textile article supply chain. Embodimentsof the present disclosure thus improve upon existing technologies usedto form hygro yarns that include an outer sheath of cotton fibers and asingle hollow core, such as those described in U.S. Pat. No. 8,733,075,entitled, Hygro Materials For Use In Making Yarns And Fabrics, (the “075patent”). The disclosure of the 075 patent which is not inconsistentwith the present disclosure is herein incorporated by reference.

Embodiments of the present disclosure also include flat woven fabric 10formed using the hygro yarns as described herein. An exemplary flatwoven fabric 10 is shown in FIGS. 1A and 1B. In one example, the flatwoven fabric 10 may be formed to include the plied staple hygro yarns 80(see FIGS. 4A, 4B). In another example, the flat woven fabric 10 may beformed to multi-core staple hygro yarns 180 (see FIGS. 8A, 8B).

Referring to FIGS. 1A and 1B, the flat woven fabric 10 includes a warpcomponent having warp yarns 20, and a weft component including weftyarns 40 that are interwoven with the warp yarns 20 to define the wovenfabric. The warp yarns 20 extends along a warp direction 4 and the weftyarns 40 extend along a weft or fill direction 6 that is perpendicularto the warp direction 4. The woven fabric 10 includes a face 12, andback 14 opposite the face 12 along a thickness direction 8 that isperpendicular to the warp direction 4 and the weft direction 6. Asillustrated, either or both of the warp component and the weft componentmay include the various hygro yarn configurations described herein. Inone example, either or both of the warp component and the weft componentthe plied hygro yarn 80 as described herein. In another example, eitheror both of the warp component and the weft component may include themulti-core yarns 180 as describe herein. The flat woven fabrics 10 asdescribed herein are suitable for bedding applications, such as sheetingfabrics. Accordingly, the flat woven fabric 10 can be converted into asheeting article.

The woven fabric 10 as described herein may be defined by a number ofdifferent woven structures or woven design repeats. As used herein, awoven design repeat includes at least a first warp yarn 20 a, a secondwarp yarn 20 b, and at least one weft yarn 40. For example, a plainweave fabric has a woven design repeat that includes two adjacent warpyarns 20 and two adjacent weft yarns 40. Depending on the particulardesign, woven design repeats may repeat along: a) the weft direction 4;b) the warp direction 6; or both the weft direction 4 and warpdirections 6. However, the design of the woven fabric 10 is not limitedto a plain weave. For example, the woven fabric can have a number ofexemplary woven structures including, but are not limited to: plainweaves; basket weaves, rib weaves (e.g. 2×1 rib weave; 2×2 rib weave; or3×1 rib weave) twill weaves; oxford weaves; percale weaves, satin weaves(e.g. satin dobby base, satin stripe satin 5/1, satin 4/1 satin; 4/1satin base strip; 4/1 stain swiss dot; 4/1 down jacquard; 5/1 satins),or sateen weaves. In one example, the woven fabric is a plain weave. Inanother example, the woven fabric is a basket weave. In another example,the woven fabric is a rib weave. In another example, the woven fabric isa twill. In another example, the woven fabric is an oxford weave. Inanother example, the woven fabric is a satin weave. Furthermore, anumber of exemplary satin constructions are possible. For instance, inone satin weave example, the woven fabric is a 4/1 satin. In anotherexample, the woven fabric is a 4/1 satin dobby diamond weave. In anotherexample, the woven fabric is a 4/1 satin dobby stripe. In yet anotherexample, the woven fabric is a 4/1 satin jacquard weave. In anotherexample, the woven fabric is a 5/1 satin. In still another example, thewoven fabric may be a 6/1 satin. In another example, the woven fabric isa 7/1 satin. In yet another example, the woven fabric is a 8/1 satin. Inanother example, the woven fabric is a 9/1 satin. And in anotherexample, the woven fabric is a 10/1 satin.

The present disclosure can utilize co-insertion techniques to insertmultiple weft yarns 40 along a weft insertion path 19 in a single weftinsertion event during weaving, as will be further detailed below. Theweft insertion path 19 of weft yarn 40 is shown in dashed lines in FIG.1B. As used herein, the weft insertion path 19 extends along the weftdirection 4 around the warp yarns 20 across an entirety of the width ofthe woven fabric 10. As illustrated, the weft insertion path extendunder (with respect to the sheet) warp 20 a, over warp yarn 20 b, underwarp yarn 20 c, and over warp yarn 20 d. A person of skill in the artwill appreciate that the weft insertion path 19 varies from one wovendesign to another woven design. By inserting groups of multiple weftyarns into the shed during a weft insertion event, it is possible toattain increased weft (or pick or fill) densities and therefore higherthread counts. Thus, the woven fabric 10 as described herein may beconstructed to have higher weft yarn densities than what is otherwisepossible, and thus higher thread counts, yet the woven fabric 10exhibits desirable fabric quality, softness, hand, and drape suitablefor bedding applications. The thread count of the woven fabrics made inaccordance with present disclosure are typically greater than about 100and can be as high as about 1000 (or even higher). The thread count asused herein is the total number of yarns in square inch of fabric. Thethread count in this context is based on total number of yarn ends. Inother words, plied yarns are considered one yarn for the purpose ofdetermining thread count.

The present disclosure can utilize co-insertion techniques to insertmultiple weft yarn 40 along a weft insertion path 19 in a single weftinsertion event during weaving, as will be further detailed below. A“co-insertion” technique is were multiple pick or weft yarns areinserted into the warp shed at one time during weaving. In co-insertion,two pick yarns supplied from two different yarn packages are inserted atone time through the shed during weaving. Co-insertion may also includeinserting three or more yarns supplied from the three or more differentyarn packages into the shed during weaving. In one example, the wovenfabric 10 has between one (1) weft yarn and seven (7) weft yarnsinserted during a single insertion event, i.e. along the weft insertionpath 19.

The warp yarns and weft yarns are arranged to achieve desired warp andweft end densities, respectively, and thus desired thread count, forbedding applications. In accordance with an embodiment of the presentdisclosure, the woven fabric has a warp end density between about 50warp ends per inch and about 350 warp ends per inch. In one example, thewarp end density is between about 50 and 150 warp ends per inch. Inanother example, the warp end density is between about 150 and 250 warpends per inch. In another example, the warp end density is between about250 and 350 warp ends per inch. Furthermore, the weft yarns are arrangedto define a weft end density between about 50 weft yarns per inch andabout 700 weft yarns per inch (or more). In one example, the weft yarndensity is between about 100 and about 700 weft yarns per inch. In oneexample, the weft yarn density is between about 100 and about 300 weftyarns per inch. In another example, the weft yarn density is betweenabout 300 and about 500 weft yarns per inch. In another example, thewell yarn density is between about 500 and about 700 weft yarns perinch. The weft yarn density has used herein refers to the total numberof separate weft yarns along a length of the woven fabric. For example,a weft yarn density of about 50 picks per inch refers the 50 total weftyarns per inch of woven fabric. If the weft yarn groups are insertedduring a single weft insertion event and each group includes three (3)weft yarns, then there would be about 16 total weft yarn groups per inchof fabric and 48 picks per inch.

The yarns can have a range of counts for the different fibers and wovenconstructions as described herein. The yarn count as used in thisparagraph refers to the yarn count for each single end in the pliedhygro yarn 80, and the yarn count of the multi-core yarn 180. The yarncount can range between about 8 Ne (664 denier) to about 120 Ne (44.3denier). In one example, the yarns can have a count in a range betweenabout 8 Ne (664 denier). In one example, the yarns can have a count in arange between about 20 Ne (266 denier). In one example, the yarns canhave a count in a range between about 30 Ne (177 denier). In oneexample, the yarns can have count in a range between about 40 Ne (133denier). In another example, the yarns has a count of about 60 Ne (88.6denier). In another example, the yarns have a count of about 70 Ne (75.9denier). In another example, the yarns have a count of about 80 Ne (66.4denier). In another example, the yarns have a count of about 100 Ne(53.1 denier). In another example, the yarns have a count of about 120Ne (44.3 denier). For flat woven fabrics, the warp yarn counts may rangefrom 20 Ne (266 denier) to about 100 Ne (53.1 denier). The weft yarncounts may range from 20 Ne (266 denier) to about 120 Ne (44.3.1denier).

The flat woven fabric 10 can use different yarn constructions in thewarp and weft components. In one example, the warp yarns are typicalstaple spun yarns (cotton or any fiber blends) and the weft yarnsinclude plied hygro yarns 80 or multi-core hygro yarns 180. In oneexample, the warp yarns are typical continuous filament yarns and theweft yarns are plied hygro yarns 80 or multi-core hygro yarns 180. Inanother example, the weft yarns are typical staple spun yarns and thewarp yarns are plied hygro yarns 80 or multi-core hygro yarns 180. Inone example, the weft yarns are typical continuous filament yarns andthe warp yarns are plied hygro yarns 80 or a multi-core hygro yarns 180.In one preferred embodiment, the warp yarns are typical staple spunyarns and the weft yarns include plied hygro yarns 80 or multi-corehygro yarns 180.

In accordance with an alternative embodiment of the present disclosure,the hygro yarns can be used to form other types of woven fabrics, forexample, a terry fabric 110 as shown in FIG. 2. As can be seen in FIG.2, in accordance with an alternative embodiment, a terry woven fabric110 is illustrated that includes a ground component 130 that includeswarp yarns 120 and weft yarns 140 interwoven with the warp yarns 120.The terry woven fabric 110 also includes one or more pile components 150a, 150 b. The ground component 130 includes a first side 32 and a secondside 34 opposite the first side. The pile component 150 a and 150 bextend away from opposite sides 32 and 34 of the ground component 130along a thickness direction 8. The warp yarns 120 extend along a warpdirection 4, which is perpendicular to the weft direction 6 and thethickness direction 9. The weft yarns 140 extend along a weft or filldirection 6 that is perpendicular to the warp direction 4. The wovenfabric 110 includes a face 12, and back 14 opposite the face 12 along athickness direction 8 that is perpendicular to the warp direction 4 andthe weft direction 6. The terminal ends of the pile components 150 a and150 b can define the face 12 and back 14 of the woven fabric 110. Thepiles have a pile height H that extends from the ground component to theterminal ends of the piles.

As illustrated in FIG. 2, the terry woven fabric 110 includes a firstpile component 150 a and a second pile component 150 b. However, theterry fabric may include only the one pile component. Each pilecomponent 150 a, 150 b includes a plurality of piles 152 a, 152 b thatproject in a direction away from the ground component 130. The piles 152a, 152 b are defined by pile yarns 154 a, 154 b interwoven with theground component 130. The terry woven fabric 110 can be formed using anyof the hygro yarn configurations described in the present disclosure. Inone example, the pile yarns 154 a, 154 b may include the plied hygroyarns 80. Furthermore, one or both of the warp yarns 120 and the weftyarns 140 may include the plied hygro yarns 80. In another example,however, the pile yarns 154 a, 154 b may include the multi-core yarns180. In such an example, one or both of the warp yarns 120 and the weftyarns 140 may include the multi-core yarns 180. The terry woven fabrics110 may be converted bath and/or kitchen products, such as towelarticles. Terry articles include a towel, a hand towel, a wash cloth, abath robe, a rug, a kitchen towel, and the like.

FIGS. 3A-6 illustrate the intermediate plied yarns 60, plied hygro yarns80, and processes used form textile articles with the plied hygro yarns80. Each of the yarns shown in FIGS. 3A-4B is a plied yarn structuremade of a plurality of separate, packaged dyed yarns twisted togetherinto a plied yarn configuration. The yarn structures before and afterremoval of the soluble fibers is illustrated in FIGS. 3A-3B and 4A-4B,respectively. FIGS. 3A and 3B illustrates a plied yarn 60 with twostaple yarns 62 a and 62 b, each having an outer sheath 84 a,84 b ofstaple fibers and a core 66 a, 66 b of soluble fibers. A plied yarn withcores of soluble fibers may be referred to as an intermediate plied yarn60. FIGS. 4A and 4B illustrate the plied yarn 80 after the solublefibers have been removed, for instance via yarn or packaging dyeing. Theplied yarn 80 has a plurality of separate packaged dyed staple yarns 82a, 82 b twisted together into the plied yarn configuration. Each packagedyed staple yarn has a hollow core 88 a, 88 b surrounded by the outersheath 84 a, 84 b of staple fibers. As illustrated, the plied stapleyarn 80 is a two-ply yarn that includes a first staple yarn 82 a and asecond staple yarn 82 b twisted with the first staple yarn 82 a todefine the two-ply yarn 80. However, the plied staple yarn can have morethan two separate yarns. A plied yarn with cores of soluble fibersremoved is referred to as a plied hygro yarn 60 or plied yarn 60. Boththe intermediate yarn 60 and the plied hygro yarn will be described inmore detail next.

Referring to FIGS. 3A-4B, the intermediate yarn 60 includes an outersheath of staple fibers and an inner core of soluble fibers. The outersheath 84 a, 84 b of staple fibers may by cotton fibers. Alternatively,for example, in place of cotton, the outer sheath may contain viscosefibers, modal fibers, silk fibers, modal fibers, linen fibers, bamboofibers, acrylic fibers, polyethylene terephthalate (PET) fibers,polyamide fibers, or blends of fibers. Fiber blends, for example, mayinclude, but are not limited to: cotton and viscose fiber blends; cottonand modal fiber blends; cotton and silk fiber blends; cotton and modalfibers, cotton and linen fiber blends; cotton and bamboo fiber blends;cotton and acrylic fiber blends; cotton and PET fiber blends; cotton andpolyamide fiber blends; viscose and modal fiber blends; viscose and silkfiber blends; viscose and modal fibers, viscose and linen fiber blends;viscose and bamboo fiber blends; viscose and acrylic fiber blends;viscose and PET fiber blends; viscose and polyamide fiber blends; PETand viscose fiber blends; PET and modal fiber blends; PET and silk fiberblends; PET and modal fibers, PET and linen fiber blends; PET and bamboofiber blends; PET and acrylic fiber blends; and PET and polyamide fiberblends. The sheath may, for example, be 100% cotton or a combination ofany of the foregoing blends.

The inner core of soluble fibers may be water soluble fibers. In oneexample, the water soluble fibers are polyvinyl alcohol (PVA) fibers.PVA fibers are synthetic fibers available in the form of filaments andcut staple fibers. PVA fibers are preferably easily dissolved in warm orhot water at about 50 degrees Celsius to about 110 degree Celsiuswithout the aid of any chemical agents. However, it should beappreciated that other fibers that can be removed and/or dissolved withwater or other specific agents that can leave an outer sheath of fibersintact may be used. The description here refers to use of PVA fibers andwater soluble fibers interchangeably for ease of illustratingembodiments of the present disclosure. The present disclosure is notlimited to PVA fibers unless the claims recite PVA fibers. The amount ofsoluble fibers dissolved depends, in part, on the count of the yarn oryarns used. The amount of soluble fibers present can vary from about 5%to about 40% of the weight of the yarn. The balance of the weight iscomprised of the outer sheath of staple fibers. In one example, thesoluble fibers may vary from about 10% to about 30% of the weight of theyarn. In one example, the soluble fibers may vary from about 15% toabout 25% of the weight of the yarn. In one example, the soluble fibersmay vary from about 17% to about 23% of the weight of the yarn. In oneexample, the soluble fibers may be about 20% of the weight of the yarn.However, it should be appreciated that the amount of soluble fibers canbe any specific amount between 5% to about 40%. Each intermediate yarns62 a, 62 b may include similar soluble fiber content. In otherembodiments, however, the weight content of the water soluble fibersbetween the first intermediate yarn 62 a and the second intermediateyarn 62 b can vary with respect to each other.

In accordance with illustrated embodiment, the intermediate plied yarns60 (or separate intermediate yarns 62 a, 62 b) are dyed prior to fabricformation to remove the core 66 a, 66 b of soluble fibers and applycolor to the staple fibers in the outer sheath 84 a, 84 b. Followingremoval of the core 66 a, 66 b of soluble fibers, each yarn has an outersheath 84 a, 84 b of staple fibers twisted around a hollow core todefine the plied yarn 80 as illustrated in FIGS. 4A and 4B. Bydissolving the soluble fibers, e.g. PVA fibers, hollow air spaces areformed throughout the yarns, corresponding to an increase in the airspace in the yarn. By increasing the air space in the yarn, the textilearticles formed therefrom are softer and bulkier than textile articlesmade without the hygro yarns as described herein.

Turning to FIGS. 4A and 4B, removal of the soluble fibers from theintermediate yarn 60 results in a plied staple yarn 80 having aplurality of separate, package dyed staple yarns 82 a, 82 b that eachinclude a hollow core. As illustrated in FIGS. 4A and 4B, the pliedstaple yarn 80 includes a first package dyed staple yarn 82 a and asecond package dyed staple yarn 82 b twisted with the first staple yarn82 a to define a two-ply yarn. Each separate dyed staple yarn 82 a, 82 bincludes an outer sheath 84 a, 84 b of staple fibers (which werepreviously dyed) twisted together around a hollow core 88 a, 88 b. Theplied yarn 80 extends along a length L that is aligned with a plied yarncentral axis A. Accordingly, it can be said that the first and secondstaple yarns 82 a, 82 b extend along the length L of the plied yarn 80.However, as can be seen in the figures, the first dyed staple yarn 82 aand the second dyed staple yarn 82 b are twisted with respect to eachother and about the central axis A. As can be seen in FIGS. 4A and 4B,the first staple yarn 82 a has a first central axis B 1. The outersheath 84 a of fibers in the first dyed staple yarn 82 a is twistedabout the first central axis B1 such that the hollow core 88 a extendsalong the first central axis B1. Likewise, the second dyed staple yarn82 b has a second central axis B2. The outer sheath 84 b of fibers inthe second dyed staple yarn 82 a are twisted about the second centralaxis B2 such that the hollow core 88 b extends along the second centralaxis B2. The plied yarn 80 defines a helical type structure whereby thefirst and second central axes B1 and B2 twist around the plied yarncentral axis A and with respect to each other.

The hollow cores 88 a, 88 b comprise a predefined portion of separate,dyed staple yarns 82 a and 82 b. The predefined portion may be describedin terms of a percentage of yarn cross-sectional dimension (e.g.distance) and/or volume of the dyed staple yarn 82 a, 82 b or plied yarn80. For instance, each dyed staple yarn 82 a, 82 b defines a yarncross-sectional dimension C1 that is perpendicular to the yarn centralaxis A and the respective yarn central axis B1, B2 (FIG. 4B). The hollowcore 88 a, 88 b defines a cross-sectional dimension C2 that isperpendicular to the respective yarn central axis B1, B2 (FIG. 4B). Inthis instance, the cross-sectional dimension C2 of the hollow core isaligned with the yarn cross-sectional dimension C1 of separate stapleyarn 82 a, 82 b along a direction G. In other words, the cross-sectionaldimensions C1 and C2 are defined along a similar direction G. The phrase“cross-sectional dimension” is the longest distance across a point ofreference in the yarn structure. For instance, an idealized yarnstructure has a circular cross section. In that case the cross-sectionaldimension would be referred to as the diameter of the yarn. However,yarn structures may not have a perfectly circular cross-section.Furthermore, in practice, it is believed the collapse of the yarnstructure, fiber migration, and twist variances along the length coulddistort the cross-sectional shape of the hollow core. Thecross-sectional dimension may be measured using image analysistechniques to obtain relative measurements of the yarn dimensions. Inaccordance with the illustrated embodiment, the hollow core 88 a, 88 bdefines between about 8% to about 40% of the cross-sectional dimensionC1 of the dyed staple yarn 82 a, 82 b. In other words, the hollow corehas a cross-sectional dimension C2 that is between about 8% to about 40%of the cross-sectional dimension C1 of the staple yarn 82 a, 82 b. Thispercentage corresponds to the approximate weight percentage of watersoluble fibers in the intermediate staple yarns 62 a, 62 b before removeof the water soluble fibers. In one example, the hollow core definesbetween about 10% to about 30% of the cross-sectional dimension C1. Inanother example, the hollow core defines between about 15% to about 25%of the cross-sectional dimension C1.

Similarly, the hollow core 88 a, 88 b comprises a defined volumepercentage of the dyed staple yarns. Volume percentage is determinedassuming that the dyed staple yarns 82 a, 82 b are cylindrical. A personof skill would appreciate the use of volume percentage based on thisassumption. The yarn volume V1 is equal to [π(C1/2)]*h, where C1 is thecross-sectional dimension C1 defined above and h is a given length L ofthe yarn 82 a, 82 b. The hollow core volume V2 is equal to [π(C2/2)²]*h,where C2 is the cross-sectional dimension C2 of the hollow care definedabove and h is a given length L of the yarn 82 a, 82 b. The volumepercentage of the hollow core is equal to (V2/V1)*100. In accordancewith the illustrated embodiment, the hollow core 88 a, 88 b comprisesbetween about 8% to about 40% of the volume of the dyed staple yarn 82a,82 b. In one example, the hollow core 88 a, 88 b defines between about10% to about 30% of the volume of the dyed staple yarn 82 a, 82 b. Inanother example, the hollow core 88 a,88 b defines between about 15% toabout 25% of the volume of the dyed staple yarn. The volume percentageof the hollow core 88 a, 88 b also corresponds to the approximate weightpercentage of water soluble fibers in the intermediate staple yarns 62a, 62 b before remove of the water soluble fibers.

The plied yarn 80 can be twisted to have ether a z-twist or a s-twist.Each yarn in the plied yarn can have a twist direction that is oppositeto the twist direction of the plied yarn. For instance, if the pliedyarn has a Z-twist, each yarn end will have an s-twist and vice versa.Furthermore, while a two-ply yarn is illustrated in the figures, theplied yarn 80 as described herein is not limited to two-plies. The pliedyarns can be 3-ply or 4 ply yarns. In one example, the plied yarn is athree-ply yarn that includes a first package dyed staple yarn, a secondpackage dyed staple yarn, and a third package dyed staple yarn twistedinto a plied structure.

The plied yarns 80 are formed to have strength sufficient for formationinto the woven fabrics 10 and 110. In conventional hygro yarns, such asthose disclosed in the 075 patent, the water soluble fibers are removedafter fabric formation. Hence, during manufacturing, the hygro yarnshave a weight and strength that is suitable to withstand the rigors ofthe weaving process. In present disclosure, however, the water solublefibers are removed before weaving, as will be further explained below.This results in a generally lower mass of yarn, if for example, singleend yarns are used during weaving. The loss of mass in the yarn due tothe removal of water soluble fibers decreases yarn strength. The presentembodiment balances this decrease in strength by plying the singled endyarns together prior to removal of the water soluble fibers.Accordingly, each package dyed staple yarn 82 a, 82 b has a strengththat is less than the tensile strength of the plied yarns 80. In certainexemplary cases, each package dyed staple yarn 82 a, 82 b may not bewell suited to withstand the rigors of the weaving cycle, whether usedas warp or weft yarns, due to the hollow core. Plied yarns 80, however,can be woven into fabrics 10 and 110 due to the increased strength andare suitable for withstanding the weaving motions and forces applied theyarn structures during weaving.

Forming the plied yarn 80 illustrated in FIGS. 4A-4B into textilearticles will be described next. FIGS. 5 and 6 illustrate a method 200for manufacturing hygro textile articles with the plied yarns 80according to an embodiment of the present disclosure. The method 200described below refers to use of cotton fiber in the outer sheath and ofPVA fibers used to form the inner core. However, it should beappreciated that other fibers can be used in the outer sheath and aninner core, as described above.

The method 200 illustrated includes two preliminary phases: outer sheathsliver formation 202 and soluble fiber sliver formation 204. Outersheath sliver formation 202 creates slivers used to form the outersheath 84 as, 84 b, of fibers in the intermediate yarns 62 a, 62 b whilesoluble fiber sliver formation 204 creates slivers used to form theinner core of soluble fibers 66 a,66 b in the intermediate yarns 62 a,62 b.

Outer sheath fiber formation phase 202 forms slivers of staple fibersfor roving. Outer fiber sliver formation initiates with fiber receiving206 and storage 208. In one example, the outer fibers are cotton fibers.The outer cover sliver (or outer sheath) may be made from, for example,cotton fibers or blends of cotton fiber or other fibers blends asdescribed above. Described below is an exemplary process of forming acotton slivers. The 075 patent includes properties of exemplary cottonfibers suitable for processing as described herein. For clarity ofdescription the outer sheath sliver formation phase 202 will be referredto as outer fiber sliver formation.

Next, the outer sheath fibers (or cotton fibers) are subject to anopening step 210 in a blow room. In the blow room, the cotton fibers areprocessed with a bale plucker, opener, multi-mixer, beater and a dustexmachine. After opening 201, the fibers are carded 212 on card machinesto deliver card slivers. The sliver from carding 212 is then processedthrough a breaker drawing step 214 to draw out the slivers. In oneexample of the breaker drawing step 214, the number of doublings at thefeed end can be 6 and the hank delivered is maintained at about 0.12. Incase of blended slivers, each component is separately processed throughcarding and the individual carded slivers are subsequently blendedtogether on draw frames. From breaker drawing 214, the slivers canfollow one of two processing step: a lapping step 216 or fed directlyroving step 232.

In instances where combing is needed, processing proceeds from thebreaker drawing 214 to the lapping step 216. As should be appreciated,combing is used to remove short fibers during cotton processing. In thelapping step 216, a unilap machine converts doublings into a lap offibers. The lap is processed in a combing step 218 using a comber. Thecombed cotton sliver is then passed through another finisher drawingstep 220 using a finisher draw frame. In one example, the finisher drawframe has a feed hank of 0.12 and a delivery hank of 0.75 and at speedsup to about 400 meters per minute. The sliver hank exiting the drawingstep 220 is kept relatively coarse (e.g. at 0.075) in order enablecovering of the soluble fiber sliver during roving step.

Referring back to step 214, in certain instances, the slivers producedat breaker drawing step 214 are fed directly to the roving step 232,further explained below.

The formation of the soluble slivers is described next. Soluble fibersliver formation initiates with fiber receiving 222 and storage 224. Thedescription below refers to PVA fibers. But it should be understood thatthe description below is not limiting and other soluble fibers could beused in place of or in addition to PVA fibers. In one example, thedenier of the PVA fibers may be range from about 0.9 denier to about 2.2denier. The soluble fibers have a cut length that is equal to or morethan 32 mm and equal to or shorter than 51 mm. However, other cutlengths can be used with modifications in the machine parameters duringspinning. In an exemplary embodiment, the PVA fiber is 38 mm staplelength and 1.4 denier. The 075 patent includes properties of exemplaryPVA fibers suitable for processing as described herein.

Next, the soluble fibers are subject to an opening step 226 in a blowroom in a “cotton” type spinning system. Here, the PVA fibers are firstpassed through a blow room having a feeder and a mono cylinder beateronly. Because PVA fibers are synthetic, the PVA fibers are clean andhave minimal impurities. Thus, less aggressive cleaning steps are neededduring soluble sliver formation phase 204 compared to similar phases ofprocessing cotton.

After opening 226, the PVA fibers are conveyed from the blow room tocarding 228 to form card slivers, which are coiled into sliver cans. Inone example, the carding machines are run between 100 and 120 meters perminute delivery speed and to yield a hank that can range between 0.05 to0.40. The carded slivers are then further drawn via drawing step 230 toyield the PVA sliver. During the drawing step 230, the carded sliversare passed through one or more draw frames to further orient the fibersalong the length of the sliver, i.e. to impart more parallelization, ofthe fibers. For instance, during drawing 230, the PVA slivers areinitially processed with a breaker draw frame. A second pass of drawingin a finisher draw frame is used to further arrange the PVA fibers inparallel form with respect to each other. The delivery hank from thefinisher draw frame is kept fine (e.g. at about 0.3 although it could behigher than 0.3) to enable the PVA sliver to be inserted into a centralor middle portion on the cotton fiber sliver upon entry into the speedframe. An exemplary delivery speed at the finishing frame can be between250 to 300 meters per minute. The output of the drawing step 220 arecans of PVA slivers.

After outer fiber sliver formation 202 and soluble fiber sliverformation 204, the cotton and PVA slivers are combined during roving232. During roving 232, the PVA sliver is inserted into a middle orcentral portion of the cotton sliver at a speed frame. Specifically, thesliver cans of both cotton slivers and PVA slivers are positioned at afeed end of the speed frame. Suitable arrangements, such as guidepulleys on a roving machine creel, are made for guiding the PVA sliverand the cotton sliver from the sliver cans at the creel side of thespeed frame.

The speed frame as described herein includes an inlet condenser, amiddle condenser, a main feed condenser, multiple sets of draftingrollers, and a flyer. Typically, slivers are processed through an inletzone, back drafting zone, middle drafting zone, and a forward draftingzone. The condensers are disposed along these different zones at or neartheir respective drafting rollers. The cotton sliver follows a normalpath from the back to the front of the speed frame through at least themain feed condenser. The inlet and middle condensers are incorporatedfor feeding PVA slivers at the inlet, the back and middle drafting zoneson the speed frame, to ensure that the PVA sliver stays in the middle ofthe cotton sliver. The PVA sliver, however, passes through the inletcondenser before occupying the middle portion on the cotton sliver inthe main feed condenser. The middle condenser is incorporated in theback zone of the drafting system to retain the PVA sliver in the middleof the cotton sliver, as mentioned above. As the cotton and PVA sliversemerge out of the drafting zone on the speed frame, the twist flowingfrom the flyer to the nip of the front rollers of the speed frame causesthe cotton fibers to wrap around the inner PVA sliver, thus forcing thePVA sliver into the core. The twisting and winding on to the bobbin onthe speed frame is typical as with any other cotton roving system. Forexample, clock-wise rotation of the flyer can give “Z” twist.Alternatively, the roving can have an “S” twist, by reversing thedirection of the rotation of the flyer to a counter-clockwise direction.The roving hank ranges from about 0.5 to about 5.0 hanks. In oneexample, the hank of roving can be about 0.58.

The roving step 232 described above feeds the PVA fiber roving into thepath of the cotton roving in the drafting zone of a speed frame.However, placing PVA fibers in a core of staple fibers can beaccomplished in a variety of ways. In one embodiment, the PVA fibers canbe added via core-spinning machine. In another variation, the PVA rovingis introduced in the path of cotton roving on the roving machine.Alternatively, the PVA can be added to the middle of the cotton rovingby reversing the rotation of flyer in the counter-clock-wise direction,which is opposite the direction of the normal flyer rotation. In bothsituations, the PVA fibers are placed in the middle of the cotton sliverduring the roving process to yield a roving with a core of PVA fibers.

After the roving step 232, a yarn spinning step 234 converts the rovingsinto single end intermediate yarns 62 a, 62 b. In accordance withillustrated embodiment, yarn spinning 234 is accomplished on a ringspinning frame using typical settings for forming ring spun yarns. Thespinning parameters on the ring frame are set based on the type offibers in the outer sheath and type and content of the PVA fibers in theinner core. The result of yarn spinning 234 is a single intermediatestaple yarn 62 a as illustrated in FIGS. 3A and 3B. The ring spinningframe can produce single end yarns with a count that ranges from about 8Ne to about 100 Ne. Yarns used for flat woven fabric 10 (FIGS. 1A & 1B)may have a count that ranges from 10 Ne to about 120 Ne. Yarns used forterry fabrics 110 (FIG. 2) may have a count that ranges from about 8 Neto about 50 Ne. After yarn spinning 234, the intermediate plied yarns 62a, 62 b are further packaged 236 into suitable yarn packages usingauto-coners. Those packages are then used in a plying step 238.

In plying step 238, the yarns plied into intermediate plied yarn 60 asshown in FIGS. 3A and 3B. In accordance with the illustrated embodiment,the plying step 238 uses two-for-one twisters to twist two single endyarns into a two-ply yarn. Accordingly, as shown, the intermediate pliedstaple yarn 60 is a two-ply yarn that includes a first intermediatestaple yarn 62 a and a second intermediate staple yarn 62 b twisted withthe first intermediate staple yarn 62 a to define the intermediate pliedyarn 60. The intermediate plied yarn 60 can have an overall twist perinch (TPI) from about 6.5 to about 14.5 TPI in an “S” direction. Thetwist direction can, however, be in a “Z” direction. Furthermore, thetwist configuration can be either Z over S or Z over Z. The resultantyarn counts would be about 2/8s to about 2/50s for terry fabrics.Similarly the doubled yarns for flat fabrics may be from about 2/10s toabout 2/100s. In alternative embodiments, the intermediate plied yarn 60can be 3-ply yarn. Such a 3-ply intermediate yarn includes a firstintermediate staple yarn, a second intermediate staple yarn, and a thirdintermediate staple yarn twisted into a plied structure. More plies than3 can be used as needed. After yarn plying 238, the intermediate pliedyarns 60 are wound 240 onto suitable yarn packages for furtherprocessing. For example, the plied yarn 60 can be cross-wound onto ayarn package. The yarn package may include a core and the plied yarn 60wound onto the core. The core may be perforated to aid in dyeing thecross-wound package.

Turning to FIG. 6, the next phase in the production of hygro textilearticles is soluble fiber removal, yarn dyeing, followed by fabricformation and article formation. As illustrated, the plied yarn packagesformed during the packaging step 240 are received 242 and stored 244 forlater processing in the fiber removal and coloration step 246. In step246, the soluble fibers are removed from the inner core and color isapplied to the fibers in the outer sheaths 84 a, 84 b with the pliedyarns 80 wound onto the yarn packages. The process step 246 may occur intwo phases where the soluble fibers are removed first followed byapplication of coloring agents. Alternatively, soluble fiber removal andcolor application can overlap. In accordance with the illustratedembodiment, the yarn packages are placed within a package dyeing machineand exposed to elevated water temperatures under pressure for apredetermined period of time, as will be understood by persons familiarwith convention package dyeing machines and processes. In one example,the water temperatures range from at least about 95 degrees Celsius toabout 120 degrees Celsius. In one preferred example, the temperature ofwater in the package dyeing machine during PVA removal is about 120degrees Celsius, which can ensure that all the PVA dissolves leaving thehollow inner cores in each yarn of the plied yarn structure. The resultof process step 240 is the plied yarn 80 with two yarns, each having anouter sheath of fibers and a hollow core, as illustrated in FIGS. 4A and4B.

After process step 246, the plied yarns 80 proceed to a warping step248. The warping step 248 includes typical warping operations for flatwoven fabrics 10 and/or typical warping operations for terry fabrics110. For instance, for terry fabrics 110, warping includes both groundyarn warping and pile yarn warping.

A weaving step 250 follows warping 248. The weaving step converts theyarns into woven fabrics. One or more looms, e.g. air-jet looms, rapierlooms, water-jet looms (or others) can be use during the weaving step.Each loom may utilize typical shedding mechanism, such as a dobby orjacquard type shedding mechanism. During the weaving step for the wovenfabric 10 (FIG. 1A, 1B), the warp and weft yarns can be arranged into anumber of different weaving constructions and designs as is known bypersons of skill in the art and that detailed above. For instance, theflat woven fabrics may include a plain weave, twills, rib weaves, basketweaves, percale, satins, sateens, other woven designs. In accordancewith an embodiment of the present disclosure, the weaving step forms awoven fabric to have a) a warp end density between about 50 warp endsper inch and about 350 warp ends per inch; and b) a weft end densitybetween about 50 weft yarns per inch and about 700 weft yarns per inch(or more). In one example, the weft yarn density is between about 100and about 700 weft yarns per inch. Furthermore, the flat woven fabricsmay have thread counts ranging from 100 TC to about 1000 C. The weavingstep may include co-insertion or insertion of multiple picks during asingle pick insertion event. In one example, the weaving step includesinserting between one (1) weft yarn and seven (7) weft yarns during asingle insertion event along the weft insertion path 19 (FIG. 1A).Furthermore, for woven fabrics 10, the weft yarns, warp yarns, or boththe warp and weft yarns can include the plied hygro yarns 80. The flatwoven fabrics are formed to have constructions that are suitable forbedding applications in both consumer, hospitality and/or healthcaremarkets.

In accordance with an alternative embodiment, the weaving step mayinclude weaving a terry fabrics 110. In such an embodiment, the ground,weft, and pile yarns are woven together using a loom configured forterry production. The terry fabric 110 can be 3-pick, 4-pick, 5-pick,6-pick, or 7-pick terry. In the one example, the terry fabric 110 is a3-pick terry. The pile component 150 a, 150 b can define a pile height Hthat extends from the ground component 130 to a top of a pile 154, 154 balong the thickness direction 8. The pile height can range from about2.0 to 10 mm.

The weaving step 250 results in “greige fabrics” that are furtherprocessed into textile articles. After the weaving step 250, the griegefabrics are inspected 252 and washed 254 in a washing vessel. Afterunloading the woven fabrics from the washing vessel, the water isextracted in an extractor in the typical manner to reduce the moisturecontent. Next, an opening step 256 untwists the fabric using a ropeopener, similar to the rope opener as described in the 075 patent. Adrying step 258 may use a hot air dryer to further dry the fabrics andexpose the fabrics to the desired temperature, as is typical in the art.The dried fabric is expanded to full width and then passed through astentering step 260. The stentering step 260 can help straighten thefabric.

In certain alternative embodiments for processing terry fabrics, ashearing step is used, whereby both sides of the terry fabric are passedthrough a shearing machine. The shearing machine has cutting devices,such as blades and/or a laser, which are set such that only protrudingfibers are cut and the piles are not cut. The shearing step reducedlinting during subsequent washing in use by the consumer.

After the stentering 260 (or optional shearing step), a cutting step 262cuts the woven fabrics to the desired length and width depending on theparticular end use. The next phase of processing can proceed based onparticular end-used and fabric type. Process steps 272, 274 and 276 maybe used to form articles based on a flat woven fabric 10. For flat wovenfabrics 10, after cutting 262, the cut woven fabric is stitched 272,inspected 274, and a packaged 276. Packaging 276 may include folding theformed articles and packing them into packages or containers forshipment. In an alternative embodiments, after the cutting 262,processing steps 266, 268, 276 and 278 are used to form textile articlesbased on terry fabrics 110. For terry fabrics 110, after cutting 262,the cut terry fabrics are hemmed 266, cross-cut 268, cross-hemmed 278,inspected 276, and packaged 278. A carton package step 278 follows toprepare the packages for transport to customers.

The process 200 described above utilizes a plied yarn 80 that has beenpackage dyed prior to fabric formation. Next will be described analternative process used to manufacture the multi-core hygro yarn 180and various textile structures that include the multi-core hygro yarn180.

FIGS. 7A-11 illustrate an intermediate multi-core yarn 160, multi-corehygro yarn 180, a processes 300 used form textile articles with thehygro yarns 180, and an apparatus 400 used during process 300 to formthe hygro yarn 180. The yarn structures during and after removal of thewater soluble fibers according to process 300 are illustrated in FIGS.7A-8B. FIGS. 7A and 7B illustrates an intermediate yarn 160 with twoyarns with pair of water soluble fiber cores 166 aa and 166 b. FIGS. 8Aand 8B illustrates the resulting the hygro yarn 180 after the watersoluble fibers have been removed resulting in a pair of hollow cores 188a, 188 b surround by the outer sheath 184 of staple fibers. Asillustrated, the hygro yarn 180 is a single ply two-ply yarn thatincludes a first hollow core 188 a and a second hollow core 188 btwisted with the first hollow core 188 a about a yarn central axis A todefine a multi-core hygro yarn 180.

As can be seen in FIGS. 7A-8B, the intermediate yarn 160 is formed toinclude an outer sheath of fibers 184 and an inner core 166 a, 166 a ofwater soluble fibers 168. The outer sheath 184 of fibers may be cottonfibers, similar to the embodiment described above and illustrated InFIGS. 3A-3B. Accordingly, the outer sheath of fibers 180 may include, inplace of cotton, viscose fibers, modal fibers, silk fibers, modalfibers, acrylic fibers, polyethylene terephthalate (PET) fibers,polyamide fibers, are fibers blends. Fiber blends may, for example,include: blends of cotton and bamboo; blends of cotton and sea weedfibers; blends of cotton and silver fibers; blends of cotton andcharcoal fibers; blends of PET fibers and cotton; blends of PET andviscose; blends of cotton and modal; blends of cotton; silk and modal;and any combinations thereof. The sheath may be 100% cotton or acombination of any of the foregoing blends.

The soluble fibers may be water soluble fibers as described above in theyarns 60 and 80 illustrated in FIGS. 3A-4B. In one example, the solublefibers are polyvinyl alcohol (PVA) fibers. The present embodiment,however, is not limited to PVA fibers unless the claims recite PVAfibers. The amount of soluble fibers present in the intermediate yarn160 can vary from about 5% to about 40% of the weight of the yarn 160.The balance of the weight is comprised of the outer sheath of staplefibers. In one example, the soluble fibers may vary from about 10% toabout 30% of the weight of the yarn. In one example, the soluble fibersmay vary from about 15% to about 25% of the weight of the yarn. In oneexample, the soluble fibers may vary from about 17% to about 23% of theweight of the yarn. In one example, the soluble fibers may be about 20%of the weight of the yarn. However, it should be appreciated that theamount of soluble fibers can be any specific amount between 5% to about40%.

The intermediate yarns 160 are processed to remove the water solublefibers after fabric formation, which is similar to the process asdescribed in the 075 patent. In alternative embodiments, however, theintermediate yarns 160 can be died prior to fabric formation to removethe water soluble fiber core 166 a, 66 b of water soluble fibers andapply color to the fibers in the outer sheath 184. After removal of thefirst and second water soluble fiber cores 166 a and 166 b, each yarnhas an outer sheath 184 of staple fibers twisted around a first andsecond hollow core 188 a and 188 b to define the multi-core yarn 180 asillustrated in FIGS. 8A and 8B. As discussed above, by dissolving thePVA fibers, hollow air spaces are formed throughout the yarns,corresponding to an increase in the air space in the yarns. Byincreasing the air space in the yarn, the textile articles formedtherefrom are softer and bulkier than textile articles made without thehygro yarns as described herein.

Turning to FIGS. 7A and 7B, removal of the water soluble fibers from theintermediate yarn 160 results in a multi-core yarn 180 having aplurality hollow cores 188 a, 188 b. The multi-core yarn 180 extendsalong a length L that is aligned with a yarn central axis A. Asillustrated the multi-core yarn 180 includes a first hollow core 188 aand a second hollow core 188 b. The first and second hollow cores 188 aand 188 b twist about each other along the length L. Furthermore, thefirst and second hollow cores 188 a and 188 b twist about the centralyarn axis A as they extend along the length L.

The first and second hollow cores 188 a and 188 b comprise a predefinedportion of the yarn 180. The predefined portion may be described interms of a percentage of yarn cross-sectional dimension (e.g. distance)and/or percentage of a volume of the yarn 180. For instance, themulti-core yarn 180 defines a yarn cross-sectional dimension D1 that isperpendicular to the yarn central axis A. The first hollow core 188 acan define a first core cross-sectional dimension F1. The second hollowcore 188 b can define a second cross-sectional dimension F2. The yarncross-sectional dimension D1, the first cross-sectional dimension F1,the second cross-sectional dimension F2 are aligned along the samedirection G. As discussed above, the phrase “cross-sectional dimension”is the longest distance across a point of reference in the yarnstructure. The cross-sectional dimension may be measured using imageanalysis techniques, as noted above. In accordance with the illustratedembodiment, each hollow core defines between about 4% to about 20% ofthe yarn cross-sectional dimension D1. For instance, the combined extentof the first core cross-sectional dimension F1 and the second corecross-sectional dimension F2 is between about 8% to about 40% of theyarn cross-sectional dimension D1 of the multi-core yarn 180. In otherwords, F1 plus F2 is between about 8% to about 40% of the yarncross-sectional dimension D1 of the multi-core yarn 180. In one example,the first and second hollow cores 188 a and 188 b together definebetween about 10% to about 30% of the cross-sectional dimension D1. Inanother example, the first and second hollow cores 188 a and 188 btogether define between about 15% to about 25% of the yarncross-sectional dimension D1. The percentages described above correspondto the approximate weight percentage of water soluble fibers in theintermediate yarn 160 before their removal from the yarn.

Similarly, the first and second hollow cores 188 a, 188 b comprise adefined volume percentage of the multi-core yarn 180. As describedabove, the volume percentage is determined assuming that the multi-coreyarn 180 is cylindrical. The yarn volume V1 is equal to [π(D1/2)²]*h,where D1 is the yarn cross-sectional dimension D1 defined above and h isa given length L of the yarn 180. The first hollow core volume V2 isequal to [π(F1/2)²]*h, where F1 is the cross-sectional dimension F1 ofthe first hollow core 188 a. The second hollow core volume V3 is equalto [π(F2/2)²]*h, where F2 is the cross-sectional dimension F2 of thesecond hollow core 188 a. The volume percentage of the hollow core isequal to [(V2+V3)/V1]*100. In accordance with the illustratedembodiment, the first and second hollow cores 188 a and 188 b comprisesbetween about 8% to about 40% of the volume of the multi-core yarn 180.In one example, the first and second hollow cores 188 a and 188 b definebetween about 10% to about 30% of the volume of the multi-core yarn 180.In another example, the first and second hollow cores 188 a and 188 bdefines between about 15% to about 25% of the volume of the multi-coreyarn 180. The volume percentage of the first and second hollow cores 188a, 188 b also correspond to the approximate weight percentage of watersoluble fibers in the intermediate yarn 160 before remove of the watersoluble fibers.

The multi-core yarn 180 can be twisted to have ether a z-twist or as-twist. Furthermore, the multi-core yarn 180 can be plied into a pliedyarn structure. Each yarn in the multi-core yarn in such a pliedstructure can have a twist direction that is opposite to the twistdirection of the multi-core yarn. For instance, if the plied multi-coreyarn has a Z-twist, each multi-core yarn 180 end will have an s-twistand vice versa.

Forming the multi-core yarn 180 illustrated in FIGS. 8A-8B into textilearticles will be described next. FIGS. 9 and 10 illustrate a method 300for manufacturing hygro textile articles with the multi-core yarns 180according to an embodiment of the present disclosure. FIG. 11illustrates an apparatus 400 used during spinning to help form themulti-core yarn 180. The method 300 described below refers to use ofcotton fiber in the outer sheath and of PVA fibers used to form theinner fiber cores 166 a and 166 b. However, it should be appreciatedthat other fibers can be used in the outer sheath and the inner cores,as described above.

The method 300 illustrated includes two preliminary phases: outer sheathsliver formation 302 and soluble fiber sliver formation 304. Outersheath sliver formation 302 creates slivers used to form the outersheath of fibers 184 in the intermediate yarn 160 while soluble fibersliver formation 304 creates slivers used to form the inner cores 166 aand 166 b of soluble fibers in the intermediate yarn 160.

Outer sheath fiber formation phase 302 forms slivers of staple fibersfor roving. Outer fiber sliver formation initiates with fiber receiving306 and storage 308. The outer sheath fiber formation phase 302 issimilar to the outer sheath formation phase 202 illustrated in FIG. 5.For instance, the outer sheath fibers (or cotton fibers) are subject toan opening step 310 in a blow room. In the blow room, the cotton fibersare processed with a bale plucker, opener, multi-mixer, beater and adustex machine. After opening 310, the fibers are carded 312 on cardmachines to deliver card slivers. The sliver from carding is thenprocessed through a breaker drawing step 314 to draw out the slivers. Incase of blended slivers, each component is separately processed throughcarding and the individual carded slivers are subsequently blendedtogether on draw frames. After breaker drawing 314, the slivers can befed to the speeding frame 332 or inter a lapping step 316 and combingstep 318.

For combed yarns, the draw frame slivers are processed via lapping 216.In lapping, a unilap machine convers doublings into a lap of fibers. Thelap is processed in a combing step 318 using a comber. The combed cottonsliver is then passed through another drawing step 320 using a finisherdraw frame. The output of the finisher draw frame is fed into the speedframe to make roving for later yarn spinning.

Soluble fiber sliver formation will be described next. Soluble fibersliver formation phase 304 is substantially similar the soluble fiberformation phase 204 described above and illustrated in FIG. 5.Accordingly, similar soluble fiber configurations, e.g. cut length,denier, etc., as described with respect to the sliver formation phase204 shown in FIG. 5 are used during the soluble fiber formation phase304. The soluble fiber formation phase 304 includes a receiving step322, and a storage step 324. Next, the soluble fibers are subject to anopening step 226 in a blow room in a “cotton” type spinning system.After opening 326, the PVA fibers are conveyed from the blow room tocarding 328 to form card slivers, which are coiled into sliver cans. Thecarded slivers are then further drawn via drawing step 330 to yield thePVA sliver. During the drawing step 330, the carded slivers are passedthrough one or more draw frames to further orient the fibers. Forinstance, during drawing 330, the PVA slivers are initially processedwith a breaker draw frame and a second pass of drawing uses a finisherdraw frame. The output of the drawing 330 are cans of PVA slivers thatfed into the roving step 332.

After outer fiber sliver formation 302 and soluble fiber sliverformation 304, the staple fibers (or outer fibers) and soluble fiberslivers are combined during roving 332. Roving 332 is substantiallysimilar to the roving 232 illustrated in FIG. 5 and described above. Forexample, during roving 332, the soluble fiber sliver is inserted into amiddle or central portion of the cotton sliver at a speed frame to yielda single roving 140 (FIG. 11) with a water soluble fiber core. Asdescribed above, the speed frame used in the roving step 332 includes aninlet condenser, a middle condenser, a main feed condenser, multiplesets of drafting rollers, and a flyer. The cotton sliver follows anormal path from the back to the front of the speed frame through atleast the main feed condenser. The inlet and middle condensers areincorporated for feeding PVA slivers at the inlet, the back and middledrafting zones on the speed frame, to ensure that the PVA sliver staysin the middle of the cotton sliver. The PVA sliver, however, passesthrough the inlet condenser before occupying the middle portion on thecotton sliver in the main feed condenser, similar to roving step 232described above. Alternative mechanisms for feeding PVA fiber rovinginto the path of the cotton roving in the drafting zone of a speed framecan be used as well. In one embodiment, the PVA fibers can be added viacore-spinning machine. In another variation, the PVA roving isintroduced in the path of cotton roving on the roving machine.Alternatively, the PVA can be added to the middle of the cotton rovingby reversing the rotation of flyer in the counter-clock-wise direction,which is opposite the direction of the normal flyer rotation. In bothsituations, the PVA fibers are placed in the middle of the cotton sliverduring the roving process to yield a roving with a core of PVA fibers.

Continuing with FIGS. 9 and 11, a multi-core spinning step 334 convertstwo rovings 140 and 142 into an intermediate multi-core yarn 160 usingan apparatus 400 of a spinning frame. Turning to FIG. 11, the apparatus400 includes a roving guide 404, rear rollers 408, and pre-drafting zonecondensers that exit side of the rear rollers 408. The apparatusincludes a middle roller and apron assembly 416, main drafting zonecondense 420, and front rollers 424, and a yarn guide 430. In operation,the roving ends 140 and 142 are fed separately through the draftingzones and converge at the yarn guide 430. Between rollers 428 and yarnguide 430, the ends 140 and 142 are twisted about each other into asingle end yarn structure, or intermediate yarn 160. The intermediateyarns 160 exit the rollers 428 and are wound into suitable bobbins. Instep 334, subsequent spinning following exit from the apparatus 400 isaccomplished using typical settings for forming ring spun yarns. Thespinning parameters, however, on the ring frame are set based on thetype of fibers in the outer sheath and type and content of the PVAfibers in the inner cores 166 a and 166 b. Because the input of theapparatus 400 are two ends 140 and 142 each having a water soluble fibercore, the intermediate yarn 160 exiting will be wound onto the bobbinsas a single yarn 160 having first water soluble fiber core 166 a and asecond water soluble fibers core 166 b, as illustrated in FIGS. 7A and7B.

The spinning step 334 can produce single end yarns 160 with a count thatranges from about 8 Ne to about 120 Ne. Yarns used for a flat wovenfabric 10 (FIGS. 1A & 1B) may have a count that ranges from 20 Ne toabout 120 Ne. Yarns used for terry fabrics 110 (FIG. 2) may have a countthat ranges from about 8 Ne to about 50 Ne. After yarn spinning 334, theintermediate multi-core yarn 160 can be further packaged 340 into asuitable yarn packages. Alternative, the intermediate multi-core yarn160 can be plied into a plied yarn configuration as needed.

Turning to FIG. 10, the next phase in the production of hygro textilearticles is fabric formation, soluble fiber removal and dyeing, followedby article formation. The multi-core yarn packages formed duringpackaging 340 are received 342 and stored 344 for warping 348. Thewarping step 348 includes typical warping operations for flat wovenfabrics 10. In alternative embodiment for terry production, the warpingoperations includes steps typical for terry fabrics 110: ground yarnwarping and pile yarn warping. After warping 348, a sizing step 349 canbe used to applying sizing composition to the warp ends.

A weaving step 350 follows sizing 349 and warping 348. The weaving step350 converts the yarns into woven fabrics. The weaving step 350 convertsthe yarns into woven fabrics. One or more looms, e.g. air-jet looms,rapier looms, water-jet looms (or others) can be use during the weavingstep. Each loom may utilize typical shedding mechanism, such as a dobbyor jacquard type shedding mechanism. During the weaving step for thewoven fabric 10 (FIG. 1A, 1B), the warp and weft yarns can be arrangedinto a number of different weaving constructions and designs as is knownby persons of skill in the art and that detailed above. For instance,the flat woven fabrics may include a plain weave, twills, rib weaves,basket weaves, percale, satins, sateens, other woven designs. Inaccordance with an embodiment of the present disclosure, the weavingstep forms a woven fabric to have a) a warp end density between about 50warp ends per inch and about 350 warp ends per inch; and b) a weft enddensity between about 50 weft yarns per inch and about 700 weft yarnsper inch (or more). In one example, the weft yarn density is betweenabout 100 and about 700 weft yarns per inch. Furthermore, the flat wovenfabrics may have thread counts ranging from 100 TC to about 1000 C. Theweaving step may include co-insertion or insertion of multiple picksduring a single pick insertion event. In one example, the weaving stepincludes inserting between one (1) weft yarn and seven (7) weft yarnsduring a single insertion event along the weft insertion path 19 (FIG.1A). Furthermore, for woven fabrics 10, the weft yarns, warp yarns, orboth the warp and weft yarns can include the multi-core hygro yarns 180.The flat woven fabrics are formed to have constructions that aresuitable for bedding applications in both consumer, hospitality and/orhealthcare markets.

In alternative embodiments, during the weaving step for terry fabrics110, the ground, weft, and pile yarns are woven together using a loomconfigured for terry production. The terry fabric 110 can be 3-pick,4-pick, 5-pick, 6-pick, or 7-pick terry. In the one example, the terryfabric 110 is a 3-pick terry. The pile component 150 a, 150 b can definea pile height H that extends from the ground component 130 to a top of apile 154, 154 b along the thickness direction 8. The pile height canrange from about 2.0 to 10 mm.

The weaving step 350 results in “greige fabrics” that are furtherprocessed into textile articles. After the weaving step 350, the griegefabrics are inspected 352. Following inspection 352, the fabrics caneither undergo a batch dyeing and soluble fiber dissolving step 346 a ora continuous dyeing and fiber dissolving step 356 a.

The batch dyeing and soluble fiber dissolving step 346 a includesscouring, bleaching, and dyeing dyed in a typical fashion in a fabricdyeing machine. The operating temperature is maintained in a range fromabout 95 degrees Celsius to about 120 degrees Celsius. In one example,the temperature is about 120 degrees Celsius, which can help ensure thatall the PVA fibers are dissolved in the water. The batch dyeing step 346a utilizes a liquor ratio sufficient to facilitate prompt dissolution ofthe PVA fibers, while allowing free movement of the fabric in the dyeingmachine. The liquor ratio may range from about 1:5 to about 1:30. Forexample, the liquor ratio may be 1:10, 1:12, 1:15, 1:20, 1:25, 1:22, or1:28.

During step 346 a, the fabrics are typically wound into the shape of arope prior to entering the fabric-dyeing machine. The rotation of thefabric in rope form aids in promoting rapid dissolution of the PVAfibers. The dissolution step 346 a also includes washing and rinsing thefabric. After washing, the liquor is drained and fresh water is injectedinto the machine for rinsing the fabric and to remove all the dissolvedPVA from the fabric and machine. During the washing and rinse phase, thewater is at a temperature ranging from about 55 degrees Celsius to about100 degrees Celsius Preferably, the water is at a high temperature, suchas 100 degrees Celsius. The fabric can be rinsed in hot water afterdraining to wash away any PVA residue. After unloading the woven fabricsfrom the vessel, the water is extracted material in an extractor in thetypical manner to reduce the moisture content. Next, an opening step 256untwists the fabric using a rope opener, similar to the rope opener asdescribed in the 075 patent. Following the rope opening step, a dryingstep 358 dries the fabric further.

As described above, after the inspection step 352, the griege fabric canprocessed using continuous dyeing range in a continuous dyeing step 346b using similar process temperatures as used in the batch step 346 a.After the continuous dyeing step 346 b, the woven fabric is dried 358.The drying step 358 utilizes a hot air dryer to further dry the fabricsat the desired temperature. The dried fabric is expanded to full widthand then passed through a stentering step 360. The stentering step 360can help straighten the fabric.

In certain alternative embodiments for processing terry fabrics, ashearing step is used, whereby both sides of the terry fabric are passedthrough a shearing machine. The shearing machine has cutting devices,such as blades and/or a laser, which are set such that only protrudingfibers are cut and the piles are not cut. The shearing step reducedlinting during subsequent washing in use by the consumer.

The result of process 300 is a textile article formed from a wovenfabric, such as a flat woven fabric 10 or terry fabric 110, whichinclude multi-core hygro yarns 180, as illustrated in FIGS. 8A and 8B.

Following the stentering step 360 (or optional shearing step), a cuttingstep 362 cuts the woven fabrics to the desired length and widthdepending on the particular end use. Steps 372, 374 and 376 may be usedto form textile articles based on a flat woven fabric 10. For flat wovenfabrics 10, after cutting 362, the cut woven fabric is stitched 372,inspected 376, and a packaged 376. Packaging step 376 may includefolding and packing the textile articles into packages or containers forshipment. Alternatively, after the cutting step 362, processing steps366, 368, 376 and 378 may be used to form textile articles with terryfabrics 110. For terry fabrics 110, after the cutting step 362, the cutterry fabrics length hemmed 366, cross-cut 368, cross-hemmed 378,inspected 376, and the packaged 376. A carton package step 378 followsto prepare the packages for transport to customers.

The flat woven fabric 10 formed as described includes either plied hygroyarn 80 and the multi-core hygro yarn 180 has better comfort profilescomparted to typical flat woven fabrics. The comfort profile may berelated to the flat woven fabrics ability to absorb moisture incombination with the desirable heat and moisture transfer properties.The comfort profile as described herein related to the ability of theflat woven fabric to keep a user cool in warmer environmental conditionsand warm in cooler environmental conditions. While not being bound toany particular theory, it is believed that flat woven fabrics asdescribed herein that include either plied hygro yarn 80 or multi-corehygro yarn 180 are more comfortable to the user compared to sheetingproducts made with typical yarn constructions.

The comfort profile in this context relates to heat transfer andmoisture properties of the flat woven fabrics. The heat and moisturetransfer properties can be determined in accordance with ASTM F 1868,Standard Test Method for Thermal and Evaporative Resistance of ClothingMaterials Using a Sweating Hot Plate, Part C, the entirety of which isexpressly incorporated herein by reference in its entirety. This test isreferred to herein as the “Thermal and Evaporative Resistance” test).Two exemplary flat woven fabrics were constructed and included theattributes illustrated in Table 1.

TABLE 1 Example Flat Woven Fabrics for Thermal and EvaporativeResistance Test Example A B Fiber Content 100% Cotton 100% Hygro CottonThread Count 400 400 Warp Ne 80 80 Weft Ne 80 80 EPI 196 196 PPI 201 201Weave Design Satin Satin Weight(oz/yd2) 3.61 3.997 Thickness (mm) 0.230.23

The “Thermal and Evaporative Resistance” test is a measure of heat flowfrom the calibrated test plate (heated to a skin surface temperature of35 degrees Celsius) through the flat woven fabric into the testenvironment (25 degrees Celsius, 65% RH). Heat flow is determined forboth simulated dry and wet skin conditions. Heat loss parameters can becalculated from the following thermal transport measurements.

The total thermal resistance (Rct), [(Δ° C.)(m²)/W], is the totalresistance to dry heat transfer (insulation) for a fabric including thesurface air layer. Total thermal resistance (Rct) is given by thefollowing equation:

Rct=[(TS−Ta)·A]/[H],

where Ts is the temperature of the plate surface (35° C.), Ta is thetemperature in the local environment (25° C.), A is the area of the testplate (0.01 m²), and W is the power input (W).

The intrinsic thermal resistance (Rcf), [(Δ° C.)(m²)/W], is theresistance to dry heat transfer provided by the fabric alone. Intrinsicthermal resistance (Rcf), is determined by subtracting the average drybare plate resistance (Rcbp) from the average of the total thermalresistance (Rct) of the specimens.

The bare plate thermal resistance (Rcbp), [(Δ° C.)(m²)/W], is theresistance to dry heat provided by the surface air layer as measured onthe bare plate. Bare plate thermal resistance values are shown in table3 below.

The apparent total evaporative resistance (RetA), [(ΔkPa)(m²)/W], is thetotal resistance to evaporative heat transfer for a fabric including thesurface air layer and liquid barrier (the descriptor term ‘apparent’ isadded to account for the fact that heat transfer may have an addedcondensation component in nonisothermal conditions). Apparent totalevaporative resistance (RetA) is given by the following equation:

RetA=[(Ps−Pa)A/H−(Ts−Ta)A]/Rct,

where Ps is the water vapor pressure at the surface plate (kPa), Pa isthe water vapor pressure in the local environment (kPa), A is the areaof the test plate (0.01 m²), H is power input (W), Ts is temperature atthe plate surface (35° C.), Ta is temperature at the local environment(25° C.), and Rct is the total thermal resistance as defined above.

The apparent intrinsic evaporative resistance (RefA), [([(ΔkPa)(m²)/W],is the resistance to evaporative heat transfer provided by the fabricalone. The apparent intrinsic evaporative resistance (RefA), isdetermined by the apparent total evaporative resistance (RetA) minus theaverage bare plate evaporative resistance (Rebp).

The bare plate thermal resistance (Rebp), [(ΔkPa)(m²)/W], is theresistance to evaporative heat transfer provided by the liquid barrierand surface air layer as measured on the bare plate (with liquid barrierattached).

Total heat loss (Qt), [W/m²], is an indicator of the heat transferredthrough the fabric material by the combined dry and evaporative heatloss, from a fully sweating test plate surface into the testenvironment. Total heat loss, measured at a 100% wet skin condition,indicates the highest predicted metabolic activity level that a user maysustain and still maintain body thermal comfort while in a highlystressed state in a test environment. Total heat loss (Qt) is calculatedusing the following equation:

$Q_{t} = {\frac{10{^\circ}\mspace{14mu} {C.}}{R_{cf} + {.04}} + \frac{3.57\mspace{14mu} {kPa}}{R_{et}^{A} + {.0035}}}$

The total insulation value (It), [clo], is the thermal resistancemeasured in units of clo, which indicates the insulating ability of thefabric material. Materials with higher do values provide more thermalinsulation. The clo value includes the insulation provided by the airlayer above the fabric and does not subtract it out as with Rcfdiscussed above. It (clo) values are derived using dry plate testresults, from the formula It=Rct*6.45.

The im value, or permeability index, indicates moisture-heatpermeability through the fabric on a scale of 0 (totally impermeable) to1 (totally permeable) normalized for the permeability of still air(naked skin). This comfort parameter indicates the effect of skinmoisture on heat loss as in the case of a sweating skin condition. Thisvalue includes the evaporative resistance provided by the air layerabove the sample and does not subtract it out as with RefA discussedabove. The Im value (permeability index) is calculated, using both dryand sweating plate test results, from the formula Im=0.060*(Rct/RetA).

The average values for Rct, RetA, Rcf, RefA, It, im, and Qt of theExamples A and B are shown in Table 2 below. The average bare platevalues are shown in Table 3. Weights and thicknesses for each sample aregiven in Table 1 above.

TABLE 2 Sweating Hot Plate Data Example Rct RetA Rcf RefA It Im Qt A0.080 0.00849 0.012 0.00327 0.518 0.568 720.12 B 0.080 0.00737 0.0120.00214 0.518 0.655 825.06

TABLE 3 Bare Plate Test Data Rcbp Rebp Average 0.068 0.005220Heat transfer makes it possible to predict the body heat that will flowfrom the skin surface through the flat woven fabric into the surroundingatmosphere. As illustrated in table 2 above, example B, which includedthe hygro yarn configuration, had greater heat loss in humid and sweatconditions and increased ability to transport moistures, e.g. sweat.Table 3 indicates that Evaporative Resistance (RetA) for example A isgreater than the Evaporative Resistance (RetA) for example A, indicatingthat example B allows moisture transfer more quickly to the atmosphere.The total heat loss (Qt) for example B is higher than the total heatloss for example A, indicating example B can transfer heat more quicklyto the atmosphere, which indicates the example B fabrics would keep auser more cool.

The comfort profile also relates thermal insulation properties of flatwoven fabrics used to form sheeting products. The thermal insulationproperties can be determined in terms of thermal resistance and can bemeasured accordance with ASTM F 1291 Standard Method for Measuring theThermal Insulation of Clothing Using a Heated Manikin, the entirety ofthe which is incorporated by reference into the present disclosure.Exemplary flat woven fabrics were constructed and included theattributes illustrated in Table 4.

TABLE 4 Examples for Thermal and Evaporative Resistance Test Example C DE Fiber Content 100% Cotton 100% Hygro Cotton 100% Hygro Cotton ThreadCount 400 400 400 Warp Ne 80 80 80 Weft Ne 80 70 60 EPI 196 196 196 PPI201 201 201 Weave Design Satin Satin SatinTests for thermal resistance should occur in non-isothermal conditions,such as those shown in Table 5. Prior to testing the manikin wasstabilized in the 20° C. environment within the chamber. After the bedwas made, the test session was started and the manikin was placed on themattress/fitted sheet and was covered with the accompanying top-sheet.After which the manikin was left to stabilize for 20 minutes. After the20 minute mark the conditions of the chamber would be changed from 20°C. to 25° C. Once 25° C. was reached the manikin was allowed tostabilize at which point the test session was stopped. One repetitionwas completed for each sheet set, as specified by the above referencedtest standard.

TABLE 5 Testing Conditions Thermal Resistance Air Temperature (° C.)20-25 RH (%) ~60 Air Speed (m/s) 0.2-0.4 Skin Temperature (° C.) 35Thermal resistance measurements were taken from all sections (WholeBody) as well as the front of manikin (the area completely covered bythe test sheets and not in contact with a mattress). Thermal resistancevalues were converted to units of do. The measurement of heat transferis a measure of heat flow from the manikin surface (heated to a skinsurface temperature of 35° C.) through an ensemble into the testenvironment and is determined for both simulated dry and wet skinconditions. Heat loss parameters in this context, calculated fromthermal transport measurements, include; a) the total thermal resistance(Rct) provided by the manikin, fabric ensemble, and air layers; b) thetotal evaporative resistance (Rct), [kPa·m2/W], which is the totalevaporative resistance provided by the manikin, fabric ensemble, and airlayers; c) the intrinsic thermal resistance (Rcl), [° C.·m2/W], totalthermal resistance provided by the garment ensemble only; d) theintrinsic evaporative resistance, [kPa·m2/W] is the intrinsicevaporative resistance provided by the fabric ensemble only; e) thetotal insulation value (It), [clo]; f) the Im value, or permeabilityindex; and g) the predicted heat loss potential (Qt), [W/m2], is apredicted level of the total amount of heat that could be transferredfrom the manikin to the ambient environment for a specified condition.It uses the thermal and evaporative resistance values to calculatepredicted levels of evaporative and dry heat transfer components for aspecific environmental condition. In this case the specified environmentis 25° C., 65% RH. Table 6 provides predicted heat loss values for the“Front Body” test for examples C, D and E. Table 7 provides predictedheat loss values for the “Whole Body” test for examples C, D and E.

TABLE 6 Predicted Heat Loss Data for Front Body Manikin Degrees(° C.)Example C Example D Example E 20 49.1 47.7 48.4 20.5 47.3 45.7 47.2 2146.8 44.4 46.4 21.5 46.7 43.6 46.1 22 46.7 43 45.8 22.5 47 42.3 45.8 2347 42.3 45.6 23.5 46.8 42.4 45.3 24 46.6 42.1 45 24.5 47.4 42.8 45.3 2547 43.2 45.7

TABLE 7 Text Data for Whole Body Manikin Degrees(° C.) Example C ExampleD Example E 20 48.4 47.5 46.6 20.5 46.6 45.4 45.4 21 46.1 44.1 44.7 21.546 43.3 44.4 22 46.1 42.9 44.1 22.5 46.3 42.4 44 23 46.3 42.4 43 23.546.4 42.4 43.6 24 46.3 42.2 43.6 24.5 47 42.6 43.3 25 46.7 42.7 44.1

Data listed in tables 6 and 7 are also illustrated graphically in FIGS.12A and 12B. The “front” and “whole body” data indicate that examples Dand E, which include hygro materials, have lower heat loss valuescompared to a typical flat woven fabrics that do not include any hygromaterials. The data indicates that sheeting products made from examplesD and E will tend to keep a user more cool compared to sheeting productsmade from example C.

The present application includes the following embodiments, each ofwhich are consistent with the inventive concepts as disclosed herein.

Embodiment 1

A woven fabric, comprising:

a warp component including warp yarns; and

a weft component including weft yarns interwoven with the warp yarns todefine the woven fabric, wherein at least one of a) the warp component,and b) the weft component include a plurality of plied staple yarns,

each plied staple yarn having a length and a plurality of separatepackage dyed staple yarns twisted together, each package dyed stapleyarn including an outer sheath of staple fibers twisted together, and ahollow core within the outer sheath of staple fibers, wherein the hollowcore extends along the length of the plied staple yarn.

Embodiment 2

The woven fabric of embodiment 1; wherein the plurality of plied stapleyarns have a first tensile strength adapted for formation into the wovenfabric, and each package dyed staple yarn has a second tensile strengththat is less than the first tensile strength.

Embodiment 3

The woven fabric of embodiment 1, wherein the at least one plied yarn isa two-ply yarn, and the plurality of separate package dyed staple yarnsinclude a first package dyed staple yarn and a second package dyedstaple yarn twisted with the first package dyed staple yarn to definethe two-ply yarn.

Embodiment 4

The woven fabric of embodiment 3, wherein the two-ply yarn has one of az-twist or a s-twist and each package dyed staple yarn has the other ofthe z-twist or the s-twist.

Embodiment 5

The woven fabric of embodiment 1, wherein each plied yarn is a three-plyyarn, and the plurality of separate package dyed staple yarns is a firstpackage dyed staple yarn, a second package dyed staple yarn, and a thirdpackage dyed staple yarn.

Embodiment 6

The woven fabric of embodiment 1, wherein each package dyed staple yarndefines a yarn cross-sectional dimension and the hollow core defines acore cross-sectional dimension that is aligned with the yarncross-sectional dimension along a direction, wherein the corecross-sectional dimension is between about 5% to about 40% of the yarncross-sectional dimension.

Embodiment 7

The woven fabric of embodiment 6, wherein the core cross-sectionaldimension is between about 15% to about 25% of the yarn cross-sectionaldimension.

Embodiment 8

The woven fabric of embodiment 1, wherein the staple fibers are a)cotton fibers, or b) blends of cotton fibers with one or more otherfibers.

Embodiment 9

The woven fabric of embodiment 1, wherein the warp and weft yarns arearranged to define a thread count between about 100 and about 1000.

Embodiment 10

The woven fabric of embodiment 1, wherein the weft yarns are co-insertedalong weft insertion path through the warp yarns.

Embodiment 11

The woven fabric of embodiment 1, wherein the warp end density isbetween about 50 warp ends per inch and about 350 warp ends per inch.

Embodiment 12

The woven fabric of embodiment 1, wherein the weft yarn density isbetween about 100 and about 700 weft yarns per inch.

Embodiment 13

The woven fabric of embodiment 1, wherein each package dyed staple yarnhas a count between about 20 Ne and about 120 Ne.

Embodiment 14

The woven fabric of embodiment 1, wherein the weft component includesthe plurality of plied staple yarns, and wherein each package dyedstaple yarn has a count between about 20 Ne and about 120 Ne.

Embodiment 15

The woven fabric of embodiment 1, wherein the warp component includesthe plurality of staple yarns, and wherein each staple yarn has a countbetween about 20 Ne and about 120 Ne.

Embodiment 16

The woven fabric of embodiment 1, wherein the weft component includesthe plurality of plied staple yarns, wherein each package dyed stapleyarn has a count between about 20 Ne and about 120 Ne,

wherein the warp end density is between about 50 warp ends per inch andabout 350 warp ends per inch, and

wherein the weft yarn density is between about 100 and about 700 weftyarns per inch.

Embodiment 17

A bedding article that includes the woven fabric of embodiment 1,wherein the bedding article is one or more of: a flat sheet, a fittedsheet, a pillow case, a comforter, and a pillow sham.

Embodiment 18

A process for manufacturing a flat woven fabric, comprising:

spinning a first staple yarn to include a first outer sheath of staplefibers twisted around a first inner core of water soluble fibers;

spinning a second staple yarn to include a second outer sheath of staplefibers twisted around a second inner core of water soluble fibers;

plying the first staple yarn and the second staple into a plied stapleyarn; and

winding the plied staple yarn into a yarn package;

with the plied staple yarn on the yarn package, removing the first andsecond inner core of the water soluble fibers from each one of the firstand second staple yarns in the plied staple yarn to form first andsecond hollow cores in the first and second staple yarns, respectively;and

after the removing step, weaving a plurality of the plied staple yarnsinto a flat woven fabric.

Embodiment 19

The process of embodiment 18, wherein the weaving step is weaving a flatwoven fabric having warp yarns and weft yarns, wherein at least one ofthe warp yarns and the well yarns include the plied staple yarns.

Embodiment 20

The process of embodiment 19, wherein the well yarns include the pliedstaple yarns.

Embodiment 21

The process of embodiment 19, wherein the weaving step includesinserting one or more weft yarns into warp yarns during a single weftinsertion event.

Embodiment 22

A woven fabric, comprising:

a warp component including warp yarns; and

a weft component including weft yarns interwoven with the warp yarns todefine the woven fabric, and at least one of a) the warp component andb) the weft component include a plurality of multi-core staple yarns,

each multi-core staple yarn including a length, an outer sheath oftwisted staple fibers that extends along the length, a first hollow corethat extends through the outer sheath of staple fibers along the length,and a second hollow core that extends through the outer sheath of staplefibers along the length.

Embodiment 23

The woven fabric of embodiment 22, wherein the first hollow core and thesecond hollow core are twisted around and with respect to each other aseach extends along the length.

Embodiment 24

The woven fabric of embodiment 23, wherein the outer sheath of staplefibers and the first and second hollow cores have the same twistdirection.

Embodiment 25

The woven fabric of embodiment 22, wherein each multi-core yarn definesa yarn cross-sectional dimension that is perpendicular to the length,wherein the first and second hollow cores each define a corecross-sectional dimension that is aligned with the yarn cross-sectionaldimension, wherein the combined core-cross sectional dimension comprisebetween about 5% to about 40% of the yarn cross-sectional dimension.

Embodiment 26

The woven fabric of embodiment 22, wherein the combined core-crosssectional dimensions comprise between about 15% to about 25% of the yarncross-sectional dimension.

Embodiment 27

The woven fabric of embodiment 22, wherein the staple fibers are a)cotton fibers, or b) blends of cotton fibers with one or more otherfibers.

Embodiment 28

The woven fabric of embodiment 22, wherein the warp and weft yarns arearranged to define a thread count between about 100 and about 1000.

Embodiment 29

The woven fabric of embodiment 22, wherein the weft yarns areco-inserted along weft insertion path through the warp yarns.

Embodiment 30

The woven fabric of embodiment 22, wherein the warp end density isbetween about 50 warp ends per inch and about 350 warp ends per inch.

Embodiment 31

The woven fabric of embodiment 22, wherein the weft yarn density isbetween about 100 and about 700 weft yarns per inch.

Embodiment 32

The woven fabric of embodiment 22, wherein each multi-core staple yarnhas a count between about 20 Ne and about 120 Ne.

Embodiment 33

The woven fabric of embodiment 22, wherein the weft component includesthe plurality of the multi-core staple yarns, wherein each multi-corestaple yarn has a count between about 20 Ne and about 120 Ne.

Embodiment 34

The woven fabric of embodiment 33, wherein the warp component includesthe plurality of staple yarns, wherein each staple yarn has a countbetween about 20 Ne and about 120 Ne.

Embodiment 35

The woven fabric of embodiment 22, wherein the weft component includesthe plurality of multi-core staple yarns, wherein each multi-core stapleyarn has a count between about 20 Ne and about 120 Ne,

wherein the warp end density is between about 50 warp ends per inch andabout 350 warp ends per inch, and

wherein the weft yarn density is between about 100 and about 700 weftyarns per inch.

Embodiment 36

A bedding article that includes the woven fabric of embodiment 22,wherein the bedding article is one or more of: a flat sheet, a fittedsheet, a pillow case, a comforter, and a pillow sham.

Embodiment 37

A process for manufacturing a woven fabric, comprising:

spinning staple yarns to include an outer sheath of staple fiberstwisted around a first core of water soluble fibers and a second core ofwater soluble fibers;

removing the first and second cores of water soluble fibers from eachone of the staple yarns to from a multi-core staple yarn; and

weaving the multi-core staple yarns into a flat woven fabric.

Embodiment 38

The process of embodiment 37, wherein the weaving step includes weavingwarp yarns and weft yarns with each other to define the flat wovenfabrics, wherein at least one of a) the warp yarns, and b) the weftyarns include the multi-core staple yarns.

Embodiment 39

The process of embodiment 38, wherein the weft yarns include themulti-core staple yarns.

Embodiment 40

The process of embodiment 37, wherein the weaving step occurs after theremoving step.

Embodiment 41

The process of embodiment 37, wherein the weaving step occurs before theremoving step.

Embodiment 42

The process of embodiment 37, wherein the removing step includes dyeingthe multi-core staple yarns.

Embodiment 43

The process of embodiment 37, wherein the weaving step includesinserting one or more weft yarns into warp yarns during a single weftinsertion event.

While the disclosure is described herein using a limited number ofembodiments, these specific embodiments are not intended to limit thescope of the disclosure as otherwise described and claimed herein. Theprecise arrangement of various elements and order of the steps ofarticles and methods described herein are not to be considered limiting.For instance, although the steps of the methods are described withreference to sequential series of reference signs and progression of theblocks in the figures, the method can be implemented in a particularorder as desired.

What is claimed:
 1. A woven fabric, comprising: a warp componentincluding warp yarns; and a weft component including weft yarnsinterwoven with the warp yarns to define the woven fabric, wherein atleast one of a) the warp component, and b) the weft component include aplurality of plied staple yarns, each plied staple yarn having a lengthand a plurality of separate package dyed staple yarns twisted together,each package dyed staple yarn including an outer sheath of staple fiberstwisted together, and a hollow core within the outer sheath of staplefibers, wherein the hollow core extends along the length of the pliedstaple yarn.
 2. The woven fabric of claim 1, wherein the plurality ofplied staple yarns have a first tensile strength adapted for formationinto the woven fabric, and each package dyed staple yarn has a secondtensile strength that is less than the first tensile strength.
 3. Thewoven fabric of claim 1, wherein the at least one plied yarn is atwo-ply yarn, and the plurality of separate package dyed staple yarnsinclude a first package dyed staple yarn and a second package dyedstaple yarn twisted with the first package dyed staple yarn to definethe two-ply yarn.
 4. The woven fabric of claim 1, wherein each packagedyed staple yarn defines a yarn cross-sectional dimension and the hollowcore defines a core cross-sectional dimension that is aligned with theyarn cross-sectional dimension along a direction, wherein the corecross-sectional dimension is between about 5% to about 40% of the yarncross-sectional dimension.
 5. The woven fabric of claim 1, wherein thestaple fibers are a) cotton fibers, orb) blends of cotton fibers withone or more other fibers.
 6. The woven fabric of claim 1, wherein thewarp and weft yarns are arranged to define a thread count between about100 and about
 1000. 7. The woven fabric of claim 1, wherein the warp enddensity is between about 50 warp ends per inch and about 350 warp endsper inch.
 8. The woven fabric of claim 1, wherein the weft yarn densityis between about 100 and about 700 weft yarns per inch.
 9. The wovenfabric of claim 1, wherein each package dyed staple yarn has a countbetween about 20 Ne and about 120 Ne.
 10. The woven fabric of claim 1,wherein the weft component includes the plurality of plied staple yarns,and wherein each package dyed staple yarn has a count between about 20Ne and about 120 Ne.
 11. The woven fabric of claim 1, wherein the warpcomponent includes the plurality of staple yarns, and wherein eachstaple yarn has a count between about 20 Ne and about 120 Ne.
 12. Aprocess for manufacturing a flat woven fabric, comprising: spinning afirst staple yarn to include a first outer sheath of staple fiberstwisted around a first inner core of water soluble fibers; spinning asecond staple yarn to include a second outer sheath of staple fiberstwisted around a second inner core of water soluble fibers; plying thefirst staple yarn and the second staple into a plied staple yarn; andwinding the plied staple yarn into a yarn package; with the plied stapleyarn on the yarn package, removing the first and second inner core ofthe water soluble fibers from each one of the first and second stapleyarns in the plied staple yarn to form first and second hollow cores inthe first and second staple yarns, respectively; and after the removingstep, weaving a plurality of the plied staple yarns into a flat wovenfabric.
 13. The process of claim 12, wherein the weaving step is weavinga flat woven fabric having warp yarns and weft yarns, wherein at leastone of the warp yarns and the weft yarns include the plied staple yarns.14. The process of claim 12, wherein the weft yarns include the pliedstaple yarns.
 15. The process of claim 12, wherein the weaving stepincludes inserting one or more weft yarns into warp yarns during asingle weft insertion event.
 16. A woven fabric, comprising: a warpcomponent including warp yarns; and a weft component including weftyarns interwoven with the warp yarns to define the woven fabric, and atleast one of a) the warp component and b) the weft component include aplurality of multi-core staple yarns, each multi-core staple yarnincluding a length, an outer sheath of twisted staple fibers thatextends along the length, a first hollow core that extends through theouter sheath of staple fibers along the length, and a second hollow corethat extends through the outer sheath of staple fibers along the length.17. The woven fabric of claim 16, wherein the first hollow core and thesecond hollow core are twisted around and with respect to each other aseach extends along the length.
 18. The woven fabric of claim 17, whereinthe outer sheath of staple fibers and the first and second hollow coreshave the same twist direction.
 19. The woven fabric of claim 16, whereineach multi-core yarn defines a yarn cross-sectional dimension that isperpendicular to the length, wherein the first and second hollow coreseach define a core cross-sectional dimension that is aligned with theyarn cross-sectional dimension, wherein the combined core-crosssectional dimension comprise between about 5% to about 40% of the yarncross-sectional dimension.
 20. The woven fabric of claim 16, wherein thecombined core-cross sectional dimensions comprise between about 15% toabout 25% of the yarn cross-sectional dimension.
 21. The woven fabric ofclaim 16, wherein the staple fibers are a) cotton fibers, or b) blendsof cotton fibers with one or more other fibers.
 22. The woven fabric ofclaim 16, wherein the warp and weft yarns are arranged to define athread count between about 100 and about
 1000. 23. The woven fabric ofclaim 16, wherein the warp end density is between about 50 warp ends perinch and about 350 warp ends per inch.
 24. The woven fabric of claim 16,wherein the weft yarn density is between about 100 and about 700 weftyarns per inch.
 25. The woven fabric of claim 16, wherein eachmulti-core staple yarn has a count between about 20 Ne and about 120 Ne.26. A process for manufacturing a woven fabric, comprising: spinningstaple yarns to include an outer sheath of staple fibers twisted arounda first core of water soluble fibers and a second core of water solublefibers; removing the first and second cores of water soluble fibers fromeach one of the staple yarns to from a multi-core staple yarn; andweaving the multi-core staple yarns into a flat woven fabric.
 27. Theprocess of claim 26, wherein the weaving step includes weaving warpyarns and weft yarns with each other to define the flat woven fabrics,wherein at least one of a) the warp yarns, and b) the weft yarns includethe multi-core staple yarns.
 28. The process of claim 26, wherein theweaving step occurs after the removing step.
 29. The process of claim26, wherein the weaving step occurs before the removing step.
 30. Theprocess of claim 26, wherein the removing step includes dyeing themulti-core staple yarns.